Square Battery Electrode Tab Insulation for Higher Energy Density
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Solution Overview
Problem
Existing methods for manufacturing square secondary batteries do not adequately address the need for high volume energy density and reliability, particularly in preventing unintentional short-circuiting and optimizing space usage.
Innovation Solution
A method for manufacturing a square secondary battery that includes an electrode body with positive and negative electrode plates, an outer package, a sealing plate, and insulating members disposed between the sealing plate and the electrode body to prevent short-circuiting and optimize space.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If insulating spacer is disposed between electrode body and sealing plate, then reliability is improved by preventing short-circuiting, but volume energy density deteriorates due to increased space occupation
Solution Approach 1:
The insulating spacer is designed with a through-hole structure that allows electrode tabs to pass through vertically. This dimensional change from a solid block to a perforated structure reduces the spacer's effective volume occupation while maintaining its insulating function, thereby improving volume energy density without compromising short-circuit prevention reliability.
Solution Approach 2:
The invention extracts the essential insulating function from a solid spacer structure and implements it through a thinner, perforated spacer with through-holes. By removing unnecessary material while retaining the core insulating capability, the spacer occupies less space within the battery, thus improving volume energy density while maintaining reliability.
2Quantity of substance
If insulating spacer with through-hole is used, then volume energy density is improved by reducing space occupation, but manufacturing complexity increases
Solution Approach 1:
The invention changes the structural parameters of the insulating spacer by introducing through-holes and optimizing its thickness. This parameter modification allows the spacer to achieve better space utilization while maintaining manufacturability through conventional molding or machining processes, balancing volume energy density improvement with manufacturing complexity.
3Quantity of substance
If electrode tabs are positioned closely to sealing plate, then space utilization is improved, but risk of short-circuiting increases
Solution Approach 1:
The insulating spacer acts as an intermediary component positioned between the electrode tabs and the sealing plate. This intermediary structure provides electrical insulation while allowing the tabs to be positioned close to the sealing plate for better space utilization, thus preventing short-circuiting without compromising compactness.
Solution Approach 2:
The through-hole insulating spacer enables electrode tabs to pass through in the vertical dimension while maintaining insulation in the horizontal plane. This dimensional approach allows close positioning of tabs to the sealing plate for space efficiency while the insulating material prevents short-circuiting through its dielectric properties.
Data Source
AI summary
A method of manufacturing a secondary battery including an electrode body element fabricating step in which a first electrode body element including a positive electrode plate and a negative electrode plate, and a second electrode body element including a positive electrode plate and a negative electrode plate are fabricated, a tab-connecting step in which a first positive electrode tab group of the first electrode body element and a second positive electrode tab group of the second electrode body element are connected to a second positive electrode collector, and a first negative electrode tab group of the first electrode body element and a second negative electrode tab group of the second electrode body element are connected to a second negative electrode collector, and an electrode body fabricating step in which, after the tab-connecting step, the first electrode body element and the second electrode body element are unified.